Retrofit Solutions for Operational Flexibility - GTEN.ca

Presented at the GTEN 2019 Symposium, Banff, Alberta, Canada - October 2019

The GTEN Committee shall not be responsible for statements or opinions advanced in technical papers or in symposium or meeting discussions.

Presented at the Gas Turbines Energy Network (GTEN) 2019 Symposium

Banff, Alberta, Canada - October 2019

The GTEN Committee shall not be responsible for statements or opinions advanced in technical papers or in symposium or meeting discussions.

Retrofit Solutions for Operational Flexibility

Hany Rizkalla, Director Combustion Engineering – PSM, an Ansaldo Energia Company

Katie Koch, Product Line Manager – PSM, an Ansaldo Energia Company

Mary Miolen, Sales Director – PSM, an Ansaldo Energia Company

October 21st, 2019

Ansaldo Energia

10/16/2019© 2019 Power Systems Mfg., LLC (PSM) Confidential & Proprietary Information. All Rights Reserved 2

Controlled Companies and JVs Branches and OfficesCompany Headquarters

Ansaldo Gas Turbine

Technology(China)

Ansaldo Thomassen

Gulf(Abū Dhabī )

Ansaldo Thomassen(Netherland)

Shanghai Electric

Gas Turbine (China)

Ansaldo Energia

Russia(Russia)

Ansaldo Energia

Switzerland(Switzerland)

A Ansaldo Sviluppo

Energia(Italy)

PSM(USA)

Ansaldo Nucleare

(Italy)

Ansaldo NES

(UK)

Who is PSM?


Flexible, Reliable & Multi-Platform Portfolio Improves Plant Profitability

2007

1999

2000

2016 - Present

1st to market with a sub 5 ppm DLN combustor for the B/E-class

1st to market with a true 7FA R0 solution

1st non-OEM to offer F-Class Upgrades

1st and only non-OEM to offer extended turndown to 35% load

54 GTs under Long-Term Agreements

1st to offer 25K combustors for the 501F & 7FA as standard

Fuel FlexibilityCurrent and Future Landscape of Gas Turbines


• Canada, relies on Natural gas to provide 24% of its energy production

• Canada is 4th largest NG producer

• Canada imports ~ 2.5-3 Bcf per day of Natural gas from the US

https://www.nrcan.gc.ca/sites/www.nrcan.gc.ca/files/energy/energy_fact/primary-energy-production_03-2018.png



Typical Shale Gas Constituent Ranges

(% Volume)

C1 C2 C3 CO2 N2

MWI

Variation

%

Barnett 80-95 2-12 0-6 0-3 1-8 -8%

Marcellus 79-86 3-17 1-4 0-1 0-1 -1%

Fayetteville 97 1 0 1 1 3%

New Albany 87-93 0-2 0-3 5-11 - -21%

Antrim 27-86 3-5 0-2 0-9 0-65 -78%

𝐿𝐻𝑉

𝑆𝐺𝑔𝑎𝑠 × 𝑇𝑔𝑎𝑠 Modified Wobbe Index =

Higher MWI Capability Required to Handle Shale Gas Properties



De-carbonization Putting H2 in Focus, Driving H2 Technology Growth

• Hydrogen initiative in the energy production

making large strides from a decarbonisation

and green house gas reduction standpoint.

• H2 usage problematic for NG fired - Low

Emissions Assets

H2 =

Combustor Development ProcessHow does PSM design and implement new combustor systems?


5. Instrumented

Engine Tests

2. Modeling

3. Cold flow Testing

4. Full Pressure

Combustion

Rig Tests

Validated

Performance

Models & Specs:• Pressures

• Temperatures

• Flows

• FAR

• TRZ

• Emissions

• Dynamics

1. Requirements:• Performance

• Durability

Engineering Discipline – Key to Combustor Development

LEC™ Technology Evolution


Strategically Expanding Portfolio and Capabilities

LEC I

• 2000-2001

• Sub 25ppm NOx

• Gas Only

• 8K hr/400 start CI

LEC III™• 2001 - Present

• Sub 5 ppm NOx

• Gas Only

• 55% Turndown with IBH

• 24K hr/900 start CI

• Off-Gas Fuel Flexibility

LEC NextGen• 2015 - Present

• Sub 9ppm NOx

• Gas Only & Dual Fuel

• 50-55% Turndown with IBH

• Up to 32K hr/1200 start CI

H2 Fuel Flex Addition –

sub-40% Turndown

AutoTune = Additional 5%

Turndown

Exhaust Bleed =

Additional 10% Turndown

FlameSheet™ = as low

as 25-30% Turndown

2018 and Beyond

Turndown Options

Multiple Advanced Combustor Solutions


T-DLN1 LEC III™ Ultra Low

Emissions System

LEC NextGen

Wide Range of Options For Varying Unit Applications

• Drop-In Compatible with OEM

DLN System

• Gas Only and Dual Fuel

Application with sub-9ppm

Emissions

• Demonstrated sub-5ppm!

• 32k hours / 1300 Starts Capable

System

• Enhanced Cooling and

Durability

• Fuel Flexibility Options

• Reverse Flow Venturi & Low

Flowing Cap for Ultra Low

Emissions

• Gas Only Application with sub-

5ppm emissions

• Robust Transition Piece to

Handle Increased Dynamics

without Excessive Wear

• Pilot-less “Fin Mixer”

Secondary Fuel Nozzle

• Drop-In Compatible with OEM DLN

System

• Gas Only and Dual Fuel Application

with sub-9ppm Emissions

• Enhanced Coating, Sealing, and

Bracket Configuration

• Wide Variety of Applications

FlameSheet™

501F Flamesheet

7F Drop-In Flamesheet

7F GTOP Flamesheet

• Flame Isolation – Combustor

Within Combustor For Advanced

Flame Staging

• Aerodynamic Trapped Vortex

Provides Wide Stability Margin

• High Premixer Exit Velocities For

Tolerance To Highly Reactive

Fuels

• Robust Mixing Techniques For

Improved Fuel Flexibility &

Tolerance To Fuel Wobbe Index

Variation

Combined Combustor Solution

Canadian Installation – LEC NextGen


LEC Fin Mixer

11 Fin Injectors with 8 holes each

LEC “Fin Mixer”

< 5ppm NOx

‘Pilot-

Less’

pre

mix

gas

air

LEC Transition Piece

Thermally Free Aft Mount Integrated

into Picture Frame

“Twin Pin” Bullhorn Bracket

Effusion Cooling

Extended Contact Wear Surfaces

Thick Inlet Support Ring

Patented Flexible “Dog Bone” Seals

W AR N I N G - PR O PR I ETAR Y I N FO R M ATI O N

T H I S D O C U M E N T A N D A L L D R A W I N G S S U B M I T T E D A R E T H E P R O P E R T Y O F P O W E R S Y S T E M S M F G .

Y O U M A Y N O T P O S S E S S , U S E , C O P Y O R D I S C L O S E T H I S D O C U M E N T O R A N Y I N F O R M A T I O N

I N I T , F O R A N Y P U R P O S E , I N C L U D I N G W I T H O U T L I M I T A T I O N T O D E S I G N , M A N U F A C T U R E , O R

R E P A I R P A R T S , W I T H O U T P O W E R S Y S T E M S M F G 'S E X P R E S S W R I T T E N P E R M I S S I O N . N E I T H E R

R E C E I P T N O R P O S S E S S I O N , O F T H I S D O C U M E N T A L O N E , F R O M A N Y S O U R C E , C O N S T I T U T E S

S U C H P E R M I S S I O N . P O S S E S S I O N , U S E , C O P Y I N G O R D I S C L O S U R E B Y A N Y O N E W I T H O U T P O W E R

S Y S T E M S M F G 'S E X P R E S S W R I T T E N P E R M I S S I O N I S N O T A U T H O R I Z E D A N D M A Y R E S U L T I N

C R I M I N A L A N D / O R C I V I L L I A B I L I T Y .

PSM 7EA ASSY, STANDARD - WEAR11-10-03

Secondary

Fuel

Nozzle

Primary Fuel Nozzle

and Endcover Crossfire

Tubes Flow Sleeve Transition

Piece Liner

LEC NextGen Liner

Improved Venturi Cooling and

Materials

Louvre Cooled and TBC Coated Pre-

Mixer

Extended Contact Wear Surfaces

Thick Lower Liner

Canadian Installation – LEC NextGen


• LEC NexGen Installed on 2X Baseload 7EA Heavy Duty Gas Turbines

in 2017 and 2019.

• Achieved <5ppm NOx operation across load range.

LEC III™ Combustion SystemCombustor Design for Fuel Flexibility


Industry-Leading Flexibility with High Hydrogen Capability

• LEC introduced in 1998

• In 2017, First Commercial Operation of 35% H2 Blending

Flow

Sleeve

Premix Mode

Reaction Zone

Fully Premixed

Secondary

Fuel Nozzle

Effusion Cooled

Head End Premixer

Reverse Flow

Cooled Venturi

Flow

Sleeve

Premix Mode

Reaction Zone

Fully Premixed

Secondary

Fuel Nozzle

Effusion Cooled

Head End Premixer

Reverse Flow

Cooled Venturi

Site Configuration

• 3 on 1 combined cycle units

• 3 9E LEC III™, 50Hz

• Ring manifold SFN

• 1 Steam Turbine

Off-gas (Hydrogen) fuel usage

• Nearby chemical plant produces H2 gas and provides to the site

• Up to 10% H2 by vol is consumed in the 3 GTs

• H2 is combined with Nat. Gas via Mixing Station

Conversion Scope

• Retroffited combustion system with PSM Fin Mixer Technology for

additional H2 capability

• Implemented AutoTune System with Fuel Flex.

Flexibility SolutionsLEC Operation with H2


LEC Combustion Systems Offering Low Emissions B/E Class Retrofit Solutions

• Hydrogen is key for future

GHG initiatives

• Ability to burn Hydrogen in

Low NOx Combustion

system is limited due to

flashback

• Hydrogen content improves

turndown due to higher

local flame temperature

(stability margin) and lower

CO emissions.

• LEC III™ technology able

to safely burn up to 35%

H2 by Volume

LEC III™ 9E Engine Results – Netherlands9E Commercial Engine H2 Operation with AutoTune


Automated Tuning Function For Varying H2 Content Improves Reliability

Novel “Fuel-Flex” AutoTune algorithm, allows fast acting gas constituency detection, and enables

Tuning with varying H2 content without need for gas chromatography.

SlopeNG =∆PNGCORሶm2NG

FPP ≡SlopeNGSlopeNGref

FlexSuite: AutoTuneAutoTune System Overview


AutoTune Offers a 365.25/24/7 Onsite Tuning Capability

EmissionsCEMSTuner

Fuel Split

Control

Ambient

Conditions

CDMS

PSM AutoTune System

AutoTune Box Features

• Compact, rack-mounted system

• Logic external to control system

• HMI screen seamlessly integrated

• Highly customizable to each GT

• Self learning tuning logic / highly

adaptable

• Contains fully functional CDMS

• Industrial grade electronics (Non-PC)

• Back-up safety logic

Combustion

Dynamics

Ctrl System

MkV, TXP,

T3000

Ovation

FlameSheet™ Combustion SystemHow It Works


TWO Combustors in One; Turndown, Fuel Flexibility, & Emissions Capability

Two main

fuel stages

DLN2.6

FlameSheetTM

SECTION A-ASCALE 0.250

• Turndown to 35% Load On Standard Firing Curve

• Extended Turndown Also Realized On

Reduced Low Load Firing Curve To Protect

Unit HRSG

• Extended Fuel Flexibility

• 30% Modified Wobbe Index (MWI) Variation

• Dual Fuel Capable

• Maintain Emissions Compliance Across Entire Load

Range, Including Turndown and +50°F TIT

• NOx Below 9ppm, As Low As 5ppm With

AutoTune

• CO Below 9ppm

• No Diluents

• 32K hours / 1250 Starts Inspection Interval

FlameSheet™ Attributes

Two pilot

fuel stages

Results From Recent FlameSheet™ InstallsLow DP FlameSheetTM


Customer Need:

• Improved Capacity, Improved HR

• Shale Gas Operation (up to 10-12% C2’s)

• Improved Turndown for HRSG

Achievements:

• +10% output and 2.2% HR improvement

with Low DP FlameSheetTM

• Turndown to 40% load (CO in compliance)

on reduced exhaust temp Isotherm

• Reduced NOx (sub-9ppm) at BL +50F Firing

• Reduced start time by 30 minutes

9.08.5

0.0

2.0

4.0

6.0

8.0

10.0

12.0

0.420 0.430 0.440 0.450 0.460 0.470 0.480

Dynam

ics (

psi pk-p

k)

NO

x,

CO

(ppm

dry

@ 1

5%

O2)

Ptot/Tot [%]

Peak 3 PTOT/TOT SWEEP (Tamb=92F. CTIM=81F, EVAPS OFF, DUCTS OFF)

Nox corr

CO corr

dynamics Bin1

dynamics Bin 2

dynamics Bin 3

dynamics Bin 4

dynamics Bin 5

+2.5% Tuning

Window

3.0

4.3

6.0

6.9

8.1

0

1

2

3

4

5

6

7

8

9

10

NO

x@

15%

O2 (

pp

m)

Firing Temperature (deg F)

FlameTop - Mode 4 - NOx vs Firing Temp

Peak 3PerfMaintenance

Typical 7F BL Temp

Sub 9ppm NOx @ Peak Fire (+50F) Output & Reduced HR on Shale Gas

FlameSheet™ Hydrogen ExperiencePerformance Comparison and Rig Test Data


Up to 65% H2 (Vol) Validation at F-Class Engine Conditions

• Engine emissions match High Pressure Rig Emissions within ~1 ppm of NOx

• Further validation of H2 capability is to come in the future with upgrades of hydrogen capability at site

Hydrogen Blending At Baseload Conditions

• Demonstrated 65% H2 By Volume In High Pressure Test Rig

• Maintained sub 6ppm NOx at 65% H2 By Volume

80% H2

Atm Rig

operation

2018/19 Event HighlightsB/E/F-Class Combustor Conversions, Upgrades, and Installations


• (2) 7EA LEC-NextGen Upgrades – Canada

• Proposal to Dutch Government to Grow H2 Combustor Technology Across Multi-

Platform

• 6B LEC-III® Combustor Conversion

• Final of (3) 9E LEC-III® H2 Upgrade – The Netherlands

• 6B DLN1 24k Upgrade

• 7EA LEC-III® Combustor Conversion

• 6B LEC-III® Virtual Flame Scanner Installation

• (5) 7FA FlameSheet™ Installations

Total Projects

Highlights

• Validated Increased H2 Fuel Flex – FlameSheet™ (7FA)

• 100% H2 Initiative Kick-Off – FlameSheet™

• 9E Combustor Upgrade to PSM Fin Mixer with PSM AutoTune/CDMS

• Demonstrated ability to burn up to 35% hydrogen

• LEC-NextGen lowered NOx emissions less than 9ppm / 24k

• Prior performance sub-14ppm / 12k

Market Driven GT Asset Renewal Initiative

Summary


Economical Flexibility Options – The Future is NOW

• American and Canadian energy market driving need

for flexibility

• Natural gas fired power assets poised to benefit from

available technologies to enable operational

flexibility and features to improve availability, service

life and overall lowered life cycle cost.

• LEC III™, LEC NextGen, and FlameSheet™ easily

retrofittable on existing F-Class and E-Class gas

turbines.

• Automated tuning, can offer enhanced fuel flexibility

to enable operations with shale gas, increased

hydrogen gas content, improved turndown and low

emissions.

Retrofit Solutions for Operational Flexibility - GTEN.ca

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